HR-G1700i Generator. Operator s Manual 1

Transcription

1 HR-G1700i Generator Operator s Manual 1

2 Introduction THANK YOU for purchasing a John Deere product. READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.) THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it. MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench. RIGHT HAND AND LEFT HAND sides are determined by facing the control panel end of the machine. The SERIAL NUMBER is located in the Specification or Identification Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the machine. WARRANTY is provided from your John Deere dealer for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate shown in this manual. This warranty provides you the assurance that your dealer will back products where defects appear within the warranty period. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void. PROTECT YOUR INVESTMENT... Use only John Deere Fuel Protect Fuel Stabilizer with Ethanol Protection TY27534 or TY Developed to ensure Optimum Performance and Protection. IMPORTANT...Use Year Round! Warning: This product contains lead, a chemical known to the State of California to cause birth defects or other reproductive harm. Wash your hands after handling this product. 2 Operator s Manual

3 Introduction NOTICE FEDERAL EMISSION COMPONENT DEFECT WARRANTY and CALIFORNIA EMISSION CONTROL WARRANTY are applicable to only those engines / generators complied with EPA (Environmental Protection Agency) and CARB (California Air Resources Board) emission regulations in the U.S.A. NOTICE To the engines / generators exported to and used in the countries other than the U.S.A., warranty service shall be performed by the distributor in each country in accordance with the standard Robin engine / generator warranty policy as applicable. AIR INDEX To show compliance with California emission regulations, a hang tag has been provided displaying the Air Index level and durability period of this engine. The Air Index level defines how clean an engine s exhaust is over a period of time. A bar graph scaled from 0 (most clean) to 10 (least clean) is used to show an engine s Air Index level. A lower Air Index level represents cleaner exhaust from an engine. The period of time (in hours) that the Air Index level is measured is known as the durability period. Depending on the size of the engine, a selection of time periods can be used to measure the Air Index level (see below). Descriptive Term Moderate: Intermediate: Extended: Applicable to Emissions Durability Period 50 hours (engine from 0 to 65 cc) 125 hours (engine greater than 65 cc) 125 hours (engine from 0 to 65 cc) 250 hours (engine greater than 65 cc) 300 hours (engine from 0 to 65 cc) 500 hours (engine greater than 65 cc) Notice: This hang tag must remain on the engine or piece of equipment, and only be removed by the ultimate purchaser before operation. Operator s Manual 3

4 Introduction FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE -- This emission warranty is applicable in all States, except the state of California. Fuji Heavy Industries Ltd. and Robin America Inc., Wood Dale Illinois, (herein ROBIN AMERICA ) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein engine ) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S. Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period. For the components listed under PARTS COVERED, the service dealer authorized by ROBIN AMERICA will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations. EMISSIONS COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of two years. PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty. Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. 1. Fuel Metering System a. Carburetor and internal parts (and / or pressure regulator or fuel injection system). b. Air / fuel ratio feedback and control system, if applicable. c. Cold start enrichment system, if applicable. d. Regulator assembly (gasoline fuel, if applicable). 2. Air Induction System a. Intake manifold, if applicable. b. Air filter. 3. Ignition System a. Spark plugs. b. Magneto or electronic ignition system. c. Spark advance / retard system, if applicable. 4. Exhaust manifold, if applicable. 5. Miscellaneous items used in above systems. a. Electronic controls, if applicable. b. Hoses, belts, connectors, and assemblies. c. Filter lock assembly (gaseous fuel, if applicable). OBTAINING WARRANTY SERVICE To obtain warranty service, take your engine to the nearest authorized ROBIN AMERICA. Bring your sales receipts indicating date of purchase for this engine. The service dealer authorized by ROBIN AMERICA will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order. All parts and accessories replaced under this warranty become the property of ROBIN AMERICA. WHAT IS NOT COVERED Conditions resulting from tampering, misuse, improper adjustment (unless they were made by the service dealer authorized by ROBIN AMERICA during a warranty repair), alteration, accident, failure to use the recommended fuel and oil, or not performing required maintenance services. The replacement parts used for required maintenance services. Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc. Diagnosis and inspection charges that do not result in warranty-eligible service being performed. Any non-authorized replacement part, or malfunction of authorized parts due to use of non-authorized parts. OWNER S WARRANTY RESPONSIBILITIES As the engine owner, you are responsible for the performance of the required maintenance listed in your owner s manual. ROBIN AMERICA recommends that you retain all receipts covering maintenance on your engine, but ROBIN AMERICA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the engine owner, you should however be aware that ROBIN AMERICA may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for the presenting your engine to the nearest service dealer authorized by ROBIN AMERICA when a problem exists. If you have any questions regarding your warranty rights and responsibilities, you should contact the ROBIN AMERICA customer service department at for the information. THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine. ROBIN AMERICA reserves the right to deny warranty coverage if the engine has not been properly maintained. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep maintenance records. MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AUTHORIZED BY ROBIN AMERICA. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM. If other than the parts authorized by ROBIN AMERICA are used for maintenance replacements or for the repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by ROBIN AMERICA in their performance and durability. HOW TO MAKE A CLAIM All repair qualifying under this limited warranty must be performed by a service dealer authorized by ROBIN AMERICA. In the event that any emission-related part is found to be defective during the warranty period, you shall notify ROBIN AMERICA customer service department at and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed. 4 Operator s Manual

5 Introduction CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein FUJI ) are pleased to explain the emission control system warranty on your 2004 and later Small Off-Road engine (herein engine ). In California, new engine must be designed, built and equipped to meet the State s stringent anti-smog standards. FUJI must warrant the emission control system on your engine for the periods of time described below, provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system may include parts such as the carburetor or fuel-injection system, and the ignition system. Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, ROBIN AMERICA will repair your engine at no cost to you including diagnosis, parts and labor. MANUFACTURER S WARRANTY COVERAGE: The 2004 and later engines are warranted for two (2) years. If any emission related part on your engine is defective, the part will be repaired or replaced by ROBIN AMERICA. OWNER S WARRANTY RESPONSIBILITIES: - As the engine owner, you are responsible for the performance of the required maintenance listed in your Owner s Manual. ROBIN AMERICA recommends that you retain all receipts covering maintenance on your engine, but FUJI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. - As the engine owner, you should however, be aware that FUJI may deny you warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. - Your are responsible for presenting your engine to a service dealer or warranty station authorized by ROBIN AMERICA Inc. 940 Lively Blvd., Wood Dale, IL (herein ROBIN AMERICA) as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact Robin America Inc. Customer Service Department at LIMITED WARRANTY on Emission Control Systems - California Only - FUJI warrants to the owner of the 2004 and later engine that the engine (1) has been designed, built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Resources Board, and (2) is free from defects in materials and workmanship that could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below. A. COMMENCEMENT DATE The warranty period begins on the date the engine is delivered to a first retail purchaser. B. LENGTH OF COVERAGE FUJI warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of a warranted emission-related part for a period of two (2) years after the date of delivery to the first retail purchaser. C. WHAT IS COVERED 1. REPAIR OR REPLACEMENT PARTS Repairs and replacement of any warranted part will be performed at no charge to you by an authorized service dealer or a warranty station. You may contact the Robin America Inc. Customer Service Department at to obtain the name of the nearest appropriate location where your warranty repairs are performed. 2. WARRANTY PERIOD This warranty continues for a period of two (2) years and applies only to the repair, replacement or adjustment of the component parts that are not scheduled for replacement as required maintenance. Further, component parts which are scheduled only for regular inspection to the effect of repair or replace as necessary are warranty for the warranty period. Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You will not be charged for diagnostic labor that leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized service dealer or warranty station. 4. DAMAGES If a warranted part failed causing damage to the engine components, consult an warranty station. D. WHAT IS NOT COVERED 1. This limited warranty does not cover any part which malfunctions, fails or is damaged due to failure to follow the maintenance and operating instructions set forth in the 2004 and later Owner s Manual including: a. Improper maintenance of any warranted parts. b. Improper installation, adjustment or repair of the engine or of any warranted part unless performed by an authorized service dealer. c. Failure to follow recommendations on fuel use contained in the 2004 and later Owner s Manual. d. Repairs performed outside of the authorized warranty service dealers. e. Use of parts which are not authorized by FUJI. 2. Add-on or modified parts. This warranty does not cover any part that malfunctions, fails or is damaged due to alterations by changing, adding to or removing parts from the engine. 3. Expenses incurred by processing warranty-claims. FUJI, any authorized service dealer and warranty station shall not be liable for any loss of use of the engine, for any alternative usage, for any damage to goods, loss of time or inconvenience. E. HOW TO FILE A CLAIM All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or warranty station authorized by ROBIN AMERICA. In the event that any emission-related part is found to be defective during the warranty period, you must notify the Robin America Inc. Customer Service Department at and you will be advised of the appropriate warranty service facilities where the warranty repair is to be performed. Operator s Manual 5

6 Introduction F. WHERE TO OBTAIN WARRANTY SERVICE It is recommended that warranty service be performed by the authorized dealer who sold you the engine, although warranty service will be performed by any authorized service dealers or warranty stations anywhere in the United States. When warranty repair is needed, the engine must be brought to an authorized service dealer or warranty station s place of business during normal business hours. In all cases, a reasonable time, not to exceed 30 days, must be allowed for the warranty repair to be completed after the engine is received by the authorized service dealer or warranty station. G. MAINTENANCE, REPLACEMENT AND REPAIR OF EMISSION-RELATED PARTS Only warranted engine replacement parts approved by FUJI should be used in the performance of any warranty maintenance or repairs on emission-related parts. If other than authorized parts are used for maintenance, replacement or repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized parts in performance and durability. FUJI, however, assumes no liability under this warranty with respect to parts other than authorized parts. The use of nonauthorized replacement parts does not invalidate the warranty on other components unless the non-authorized parts cause damage to warranted parts. H. PARTS COVERED UNDER THE CALIFORNIA EMISSIONS WARRANTY 1. Fuel Metering System a. Carburetor and internal parts (and / or pressure regulator or fuel, injection system). b. Air / fuel ratio feedback and control system, if applicable. c. Cold start enrichment system, if applicable. d. Regulator assembly (gaseous fuel, if applicable). 2. Air Induction System a. Intake manifold, if applicable. b. Air filter. 3. Ignition System a. Spark Plug. b. Magneto or electronic ignition system. c. Spark advance / retard system, if applicable. 4. Exhaust manifold, if applicable. 5. Miscellaneous items used in above systems. a. Electronic controls, if applicable. b. Hoses, belts, connectors, and assemblies. c. Filter lock assembly (gaseous fuel, if applicable). I. MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2004 and later Owner s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended. FUJI will not deny a warranty claim solely because you have no record of maintenance; however, FUJI may deny a warranty claim if your failure to perform required maintenance resulted in the failure of warranted part. The proof which you maintain should be given to each subsequent owner of the engine. You are responsible for performing the scheduled maintenance described below based on the procedures specified in the 2004 and later Owner s Manual. The scheduled maintenance below is based on a normal engine operating schedule. PROCEDURE: INTERVAL: 1. Change engine oil. 1. Initial 20 hours and every 100 hours afterward. 2. Clean air cleaner (element). 2. Every 50 hours. 3. Replace air cleaner element. 3. Every 200 hours. 4. Clean and adjust spark plug and electrodes. 4. Every 200 hours. NOTE: More frequent maintenance may be necessary under dusty, dirty or severe conditions. 6 Operator s Manual

7 Contents Page Safety... 9 Safety Signs Controls Preparing the Generator Operation Troubleshooting Service Storage Specifications Wire Diagram Warranty Notes All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Operator s Manual 7

8 Contents 8 Operator s Manual

9 Safety RECOGNIZE SAFETY INFORMATION This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. UNDERSTAND SIGNAL WORDS A signal word--danger, WARNING or CAUTION--is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. FOLLOW SAFETY INSTRUCTIONS Carefully read all safety messages in this manual and safety signs on your machine. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. WARNING WARNINGS IN THE MANUALS. WARNINGS IN THE MANUALS. CAUTION O CAUTIONS IN O CAUTIONS IN O THE MANUALS O THE MANUALS O CAUTIONS IN O CAUTIONS IN O THE MANUALS O THE MANUALS Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life. If you do not understand any part of this manual and need assistance, contact your John Deere dealer. Operator s Manual 9

10 CARBON MONOXIDE - POISONOUS GAS Use generator outdoors, away from open windows, vents, or doors. Keep generator at least 1 meter (3 feet) away from any structure or building during use. Generator exhaust contains carbon monoxide - a poisonous gas that can kill you. You CAN NOT smell or see this gas. Never use a generator in enclosed or partially-enclosed spaces. Generators can produce high levels of carbon monoxide very quickly. When you use a portable generator, remember that you cannot smell or see carbon monoxide. Even if you can t smell exhaust fumes, you may still be exposed to carbon monoxide. If you start to feel sick, dizzy, or weak while using a generator, get to fresh air RIGHT AWAY. DO NOT DELAY. The carbon monoxide from generators can rapidly lead to full incapacitation and death. If you experience serious symptoms, get medical attention immediately. Inform medical staff that carbon monoxide poisoning is suspected. If you experienced symptoms while indoors, have someone call the fire department to determine when it is safe to re-enter the building. NEVER operate the generator in an explosive atmosphere, near combustible materials or where ventilation is not sufficient to carry away exhaust fumes. Exhaust fumes can cause serious injury or death. NEVER use a generator indoors, including in homes, garages, basements, crawl spaces, and other enclosed or partially-enclosed areas, even with ventilation. Opening doors and windows or using fans will not prevent carbon monoxide build-up in the home. Follow the instructions that come with your generator. Locate the unit outdoors and away from doors, windows, and vents that could allow the carbon monoxide gas to come indoors. ONLY run generator outdoors and away from air intakes. NEVER run generator inside homes, garages, sheds, or other semi-enclosed spaces. These spaces can trap poisonous gases EVEN IF you run a fan or open doors and windows. If you start to feel sick, dizzy, or weak while using the generator, shut if off and get fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning. Install battery-operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up in your home, according to the manufacturer s installation instructions. The carbon monoxide alarms should be certified to the requirements of the latest safety standards for carbon monoxide alarms. (UL 2034, IAS 6-96, or CSA ). Test your carbon monoxide alarm frequently and replace dead batteries. 10 Operator s Manual

11 SAFETY WARNING WHEN REFUELING Gasoline is extremely flammable and its vapors can explode if ignited. Observe all safety regulations for the safe handling of fuel. Handle fuel in safety containers. If the container does not have a spout, use a funnel. Do not overfill the fuel tank, leave room for the fuel to expand. Do not refill fuel tank while the engine is running. Before refueling the generator, turn it off and let it cool down. Gasoline spilled on hot engine parts could ignite. Fill the tank only on an area of bare ground. While fueling the tank, keep heat, sparks and open flame away. Carefully clean up any spilled fuel before starting engine. Always fill fuel tank in an area with plenty of ventilation to avoid inhaling dangerous fumes. NEVER store fuel for your generator in the home. Gasoline, propane, kerosene, and other flammable liquids should be stored outside of living areas in properly-labeled, non-glass safety containers. Do not store them near a fuel-burning appliance, such as a natural gas water heater in a garage. If the fuel is spilled or the container is not sealed properly, invisible vapors from the fuel can travel along the ground and can be ignited by the appliance s pilot light or by arcs from electric switches in the appliance. GROUND FAULT CIRCUIT INTERRUPTER PROTECTION These generators are equipped with a GFCI (Ground Fault Circuit Interrupters) 120V duplex receptacles for protection against the hazards of electrical shock from defective attachments such as, tools, cords, and cables. WARNING: The GFCI may not function unless the g e n e r a t o r i s p r o p e r l y g r o u n d e d. F o l l o w the correct procedure specified in the section labeled GROUNDING INSTRUCTIONS. A GFCI is a device that interrupts electricity from either the utility or generator by means of a special type of circuit breaker if a fault current flow to the ground occurs. A GFCI can be used only with generators that have the neutral wire internally bonded to the frame, and the frame properly grounded to the earth. A GFCI will not work on generators that do not have the neutral wire bonded to the frame, or on generators which have not been properly grounded. All John Deere generators have internally bonded ground wires. A GFCI will not work if the unit is not properly grounded. A GFCI may be required by OSHA regulations, the National Electric Code and/or local and federal codes when operating a generator. For additional protections against shock hazards due to defective equipment attached to the twist-lock receptacles, consider the use of a GFCI on each of these receptacles as well. GFCI and GFCI protected cord sets and cables may be purchased from local electrical supply houses. Operator s Manual 11

12 ELECTRICAL HAZARDS This product must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. DANGER - IMPROPER CONNECTION OF THE EQUIPMENT- GROUNDING CONDUCTOR CAN RESULT IN A RISK OF ELECTROCUTION. CHECK WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE UNIT IS PROPERLY GROUNDED. This generator is equipped with a grounding terminal for your protection. Always complete the ground path from the generator to an external ground source as instructed in the section labeled Grounding Instructions in the Preparation section of this manual. The generator is a potential source of electrical shock if not kept dry. Keep the generator dry and do not use in rain or wet conditions. To protect from moisture, operate it on a dry surface under an open, canopy-like structure. Dry your hands if wet before touching the generator. Plug appliances directly into the generator. Or, use a heavy duty, outdoor-rated extension cord that is rated (in watts or amps) at least equal to the sum of the connected appliance loads. Check that the entire cord is free of cuts or tears and that the plug has all three prongs, especially a grounding pin. NEVER try to power the house wiring by plugging the generator into a wall outlet, a practice known as back feeding. This is an extremely dangerous practice that presents an electrocution risk to utility workers and neighbors served by the same utility transformer. It also bypasses some of the built-in household circuit protection devices. If you must connect the generator to the house wiring to power appliances, have a qualified electrician install the appropriate equipment in accordance with local electrical codes. Or, check with your utility company to see if it can install an appropriate power transfer switch. For power outages, permanently installed stationary generators are better suited for providing backup power to the home. Even a properly connected portable generator can become overloaded. This may result in overheating or stressing the generator components, possibly leading to a generator failure. 12 Operator s Manual

13 IMPORTANT SAFETY INSTRUCTIONS WARNING: To reduce the risk of injury, read this operator s manual completely before using. When using this product, the following basic precautions should always be followed: 1. Read all the instructions before using the product. 2. Do not enclose the generator nor cover it with a box. The generator has a built-in forced air cooling system, and may become overheated if it is enclosed. If generator has been covered to protect if from the weather during non use, be sure to remove it and keep it well away from the area during generator use. 3. Operate the generator on a level surface. It is not necessary to prepare a special foundation for the generator. However, the generator will vibrate on an irregular surface, so choose a level place without surface irregularities. If the generator is tilted or moved during operation, fuel may spill and/or the generator may tip over, causing a hazardous situation. Proper lubrication cannot be expected if the generator is operated on a steep incline or slope. In such a case, piston seizure may occur even if the oil is above the upper level. 4. Pay attention to the wiring or extension cords from the generator to the connected device. If the wire is under the generator or in contact with a vibrating part, it may break and possibly cause a fire, generator burnout, or electric shock hazard. Replace damaged or worn cords immediately. 5. Do not operate in rain, in wet or damp conditions, or with wet hands. The operator may suffer severe electric shock if the generator is wet due to rain or snow. 6. If wet, wipe and dry it well before starting. Do not pour water directly over the generator, nor wash it with water. 7. Be extremely careful that all necessary electrical grounding procedures are followed during each and every use. Failure to do so can be fatal. 8. NEVER try to power the house wiring by plugging the generator into a wall outlet, a practice known as back feeding. This is an extremely dangerous practice that presents an electrocution risk to utility workers and neighbors served by the same utility transformer. It also bypasses some of the built-in household circuit protection devices. If you must connect the generator to the house wiring to power appliances, have a qualified electrician install the appropriate equipment in accordance with local electrical codes. Or, check with your utility company to see if it can install an appropriate power transfer switch. 9. No smoking while charging a battery. The battery emits flammable hydrogen gas, which can explode if exposed to electric arcing or open flame. Keep the area wellventilated and keep open flames / sparks away when charging a battery. Operator s Manual 13 WARNING WARNINGS IN THE MANUALS. WARNINGS IN THE MANUALS. O CAUTIONS IN O THE MANUALS O CAUTIONS IN O THE MANUALS CAUTION O CAUTIONS IN O THE MANUALS O CAUTIONS IN O THE MANUALS

14 IMPORTANT SAFETY INSTRUCTIONS 10. Engine becomes extremely hot during and for some time after operation. Keep combustible materials well away from generator area. Be very careful not to touch any parts of the hot engine especially the muffler area or serious burns may result. 11. Keep children and all bystanders at a safe distance from work area. 12. It is absolutely essential that you know the safe and proper use of the power tool or appliance that you intend to use. All operators must read, understand and follow the tool / appliance owners manual. Tool and appliance applications and limitations must be understood. Follow all directions given on labels and warnings. Keep all instruction manuals and literature in a safe place for future reference. 13. Use only LISTED extension cords. When a tool or appliance is used outdoors, use only extension cords marked For Outdoor Use. Extension cords, when not in use should be stored in a dry and well ventilated area. 14. Always disconnect tools or appliances when not in use, before servicing, adjusting, or installing accessories and attachments. WARNING WARNINGS IN THE MANUALS. WARNINGS IN THE MANUALS. CAUTION O CAUTIONS IN O CAUTIONS IN O THE O THE MANUALS MANUALS O CAUTIONS IN O CAUTIONS IN O THE MANUALS O THE MANUALS SAVE THESE INSTRUCTIONS 14 Operator s Manual

15 WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. PREPARE FOR EMERGENCIES Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone. Be prepared if a fire starts. INSPECT GENERATOR Be sure all covers, guards and shields are tight and in place. Locate all operating controls and safety labels. Inspect power cord for damage before using. There is a hazard of electrical shock from crushing, cutting or heat damage. SERVICE GENERATOR SAFELY Before servicing the generator, disconnect all equipment and allow unit to cool down. Service generator in a clean dry flat area. Make sure the engine is stopped before starting any maintenance servicing or repair. Operator s Manual 15

16 SAFETY SIGNS In accordance with the European requirements (eec Directives), the specified symbols as shown in the following table are used for the products and this instructions manual. Read the operator's instruction manual. Fire, open light and smoking prohibited. Stay clear of the hot surface. Caution, risk of electric shock. Exhaust gas is poisonous. Do not operate in an unventilated room. Do not connect the generator to the commercial power lines. Stop the engine before refueling. HOT, avoid touching the hot areas. ON (power and Engine) IN-position of a bistable push control Engine start (Electric start) OFF (power and Engine) Protective earth (ground) Engine stop Alternating current Fuse Diesel fuel Direct current Engine oil Fast Plus ; positive polarity Add oil Slow Minus ; negative polarity Battery charging condition Run OUT-position of a bistable push control Choke ; cold starting aid Stop P r Rated power (kw) COP Continuous power COS r Rated power factor f r Rated frequency (Hz) U r Rated voltage (V) I r Rated current (A) H max Maximum site altitude above sea-level (m) T max Maximum ambient temperature ( ) m Mass (kg) 16 Operator s Manual

17 Controls CONTROLS 1-- Recoil Starter 2-- Control Panel 3-- Ground Terminal 4-- Side Panel (L) 5-- Air Cleaner 6-- Fuel Drain Screw 7-- Carrying Handle 8-- Tank Cap Cover 9-- Exhaust Outlet 10-- Oil Drain Plug 11-- Side Panel (R) 12-- Oil Gauge 13-- Spark Plug Cap Operator s Manual 17

18 Controls CONTROLS ENGINE SWITCH: (Fig. 15) The engine switch is designed for easy operation with the interlocking mechanism between the fuel valve and the choke. OUTPUT LAMP AND OVERLOAD LAMP: (Fig. 16) These lamps are turned on in the following conditions: Output Lamp (Green) --- The lamp is turned on while generating properly. Overload Lamp (Red) --- The lamp is turned on in the overload condition. If the lamp is turned on, stop and start the engine again to resume the operation. OIL SENSOR LAMP: (Fig. 17) When the level of the engine oil falls below the prescribed value, the alarm lamp lights up and the engine stops automatically. When the engine stops due to oil shortage, it can not be started anymore even by pulling the start knob (just the alarm lamp flickers). In such a case, replenish engine oil. See Pre-Operation; Engine Oil on page 21. AUTO POWER SAVE SWITCH: (Fig. 18) With the switch in the marking position, the engine speed is reduced automatically when no load is applied, while the engine speed is automatically increased when the load is applied. When using in the heavy load condition, set the switch into the marking position to maintain the engine RPM at the rated setting. When using DC power, turn the switch into the position. AC RECEPTACLES: (Fig. 19) AC electric power is available through this receptacle. Use a grounding type plug as shown on page 26, Table 1. WARNING: DO NOT PUT FOREIGN OBJECTS INTO THE PLUG RECEPTACLE. CAUTION: DO NOT PLUG MORE THAN TWO APPLIANCES INTO THE GENERATOR AT A TIME. CHOKE RUN STOP ENGINE SWITCHES OUT PUT To start the engine, turn the knob to the position. (Choke valve is closed.) Keep the knob in this position after the engine starts. (The engine can be started with the knob at the position when the engine is warm. To stop the engine, return the knob to the position. (The fuel cock is closed as well.) (Fig. 15) (Fig. 16) (Fig. 17) (Fig. 18) OVER LOAD (Fig. 19) 18 Operator s Manual

19 Controls CONTROLS DC TERMINALS: (Fig. 20) DC electric power for battery charging is available. - Red is positive (+) terminal. - Black is negative (-) terminal. DC CIRCUIT BREAKER: (Fig. 21) DC circuit breaker shuts off electric current when the current exceeds its limit or a malfunction occurs in the connected appliance. Check for excessive current consumption or defects in the appliance. After making sure everything is in order, push the button to the ON position. CAUTION: IF CIRCUIT BREAKER CONTINUES TO TRIP, CHECK APPLIANCE FOR DEFECT. IF GENERATOR IS MALFUNCTIONING, SEE YOUR AUTHORIZED JOHN DEERE SERVICE CENTER OR DEALER. NEVER INTERFERE WITH THE OPERATION OF THE CIRCUIT BREAKER KNOB OR KEEP PUSHING IT IN THE ON POSITION. IN (ON) " " Recoil Starter Handle (Fig. 20) Button Knob OUT (OFF) (Fig. 21) (Fig. 22) " " RECOIL STARTER: (Fig. 22) Pull this handle to start the generator. GROUND TERMINAL: (Fig. 23) Terminal for grounding the generator. FUEL TANK CAP: (Fig. 24) The fuel tank cap is located under the cover. To open the cover, lift up and towards the muffler end as shown in the illustration. Remove the fuel tank cap by turning counterclockwise. SIDE COVER: (Fig. 25) To access the following items for servicing, take the applicable side cover out by removing the screw with a screwdriver. LH-Side Cover - Air cleaner, etc. RH-Side Cover - Oil level gauge, Ignition Coil, Spark Plug, etc. (Fig. 23) Tank Cap Cover Fuel Tank Cap Fuel Filter Screen (Fig. 24) (Fig. 25) Operator s Manual 19

20 Preparing the Generator GROUNDING INSTRUCTIONS This product must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. DANGER - IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING CONDUCTOR CAN RESULT IN A RISK OF ELECTROCUTION. CHECK WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE UNIT IS PROPERLY GROUNDED. The ground terminal on the frame must always be used to connect the generator to a suitable ground source. The ground path should be made with #8 size wire. Connect the grounding wire securely to the ground terminal. Connect the other end of the wire securely to a suitable ground source. (Fig. 1) The National Electric Code contains several practical ways in which to establish a good ground source. Examples given below illustrate a few of the ways in which a good ground source may be established. A metal underground water pipe in direct contact with the earth for at least 10 feet can be used as a grounding source. If an pipe is unavailable, an 8 foot length of pipe or rod may be used as the ground source. The pipe should be 3/4 inch trade size or larger and the outer surface must be noncorrosive. If a steel or iron rod is used it should be at least 5/8 inch diameter and if a nonferrous rod is used it should be at least 1/2 inch diameter and be listed as material for grounding. Drive the rod or pipe to a depth of 8 feet. If a rock bottom is encountered less than 4 feet down, bury the rod or pipe in a trench. All electrical tools and appliances operated from this generator, must be properly grounded by use of a third wire or be Double Insulated. Grounding Rod (Fig. 1) Ground Terminal It is recommended to: 1. Use electrical devices with 3 prong power cords. 2. Use an extension cord with a 3 hole receptacle and a 3 prong plug at the opposite ends to ensure continuity of the ground protection from the generator to appliance. We strongly recommend that all applicable federal, state and local regulations relating to grounding specifications be checked and followed. LINE TRANSFER SWITCH If this generator is used for standby service, it must have a transfer switch between the utility power service and the generator. The transfer switch not only prevents the utility power form feeding into the generator, but is also prevents the generator form feeding out into the utility company s lines. This is intended to protect the serviceman who may be working on a damaged line. THIS INSTALLATION MUST BE DONE BY A LICENSED ELECTRICIAN AND ALL LOCAL CODES MUST BE FOLLOWED. 20 Operator s Manual

21 Preparing the Generator PRE-OPERATION ENGINE OIL: Before checking or refilling oil, be sure generator is located on stable and level surface with engine stopped. Engine Oil Dipstick 1. Remove oil dipstick and check the engine oil level. (Fig. 2) 2. If oil level is below the lower level line, refill with suitable oil to upper level line. Do not screw in the oil dipstick when checking oil level. (Fig. 3) 3. Change oil if contaminated. (See Maintenance Schedule; Changing Engine Oil page 30.) (Fig. 2) Oil Capacity gal. / 0.4 liters Recommended engine oil: John Deere PLUS-4 oil is the preferred oil to use. If John Deere PLUS-4 oil is not available, use 4-stroke automotive detergent oil of API service class SE or higher grade (SG, SH or SJ is recommended). If single viscosity oil is used, select the appropriate viscosity for the average temperature in your area. (Fig. 4) (Fig. 3) (Fig. 4) Operator s Manual 21

22 Preparing the Generator PRE-OPERATION FUELING: WARNING: WARNING: EXPLOSIVE FUEL! GASOLINE IS EXTREMELY FLAMMABLE AND ITS VAPORS CAN EXPLODE IF IGNITED. STORE GASOLINE ONLY IN APPROVED CONTAINERS, IN WELL VENTILATED, UNOCCUPIED BUILDINGS AND AWAY FROM SPARKS OR FLAMES. Red Marking (Fig. 5) DO NOT FILL THE FUEL TANK WHILE THE ENGINE IS HOT OR RUNNING, SINCE SPILLED FUEL COULD IGNITE IF IT COMES IN CONTACT WITH HOT PARTS OR SPARKS FROM IGNITION. DO NOT START THE ENGINE NEAR SPILLED FUEL. NEVER USE GASOLINE AS A CLEANING AGENT. Fuel Tank Cap Tank Cap Cover WARNING: DO NOT OVERFILL THE FUEL TANK, LEAVE ROOM FOR THE FUEL TO EXPAND. Fuel Filter Screen 1. If fuel level is low, refill with unleaded automotive gasoline. 2. Fuel level should never go over the RED marking at the inlet portion. (Fig. 5) 3. Be sure to use the fuel filter screen on the fuel filter neck. (Fig. 6) Fuel Tank Capacity gal. / 3.5 liters 4. When using the generator for the first time or stopping due to the fuel running out, pull the recoil handle several times after filling the fuel up to the RED marking at the inlet portion of the fuel tank. (Fig. 6) WARNING: MAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD. DO NOT REFILL TANK WHILE ENGINE IS RUNNING OR HOT. BEFORE FILLING FUEL, TURN THE ENGINE SWITCH TO (STOP) POSITION. BE CAREFUL NOT TO ADMIT DUST, DIRT, WATER OR OTHER FOREIGN OBJECTS INTO FUEL. WIPE OFF SPILT FUEL THOROUGHLY BEFORE STARTING ENGINE. KEEP OPEN FLAMES AWAY. 22 Operator s Manual

23 Preparing the Generator PRE-OPERATION FUELING (continued): General Recommendations Purchase gasoline in small quantities and store in clean, approved containers. To minimize gum deposits in your fuel system and to insure easy starting, do not use gasoline left over from the previous season. Do not add oil to the gasoline. Fuel Type For best results use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. Unleaded gasoline is recommended as it leaves less combustion chamber deposits. GASOLINE/ALCOHOL BLENDS: Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved, as a fuel. Other gasoline/alcohol blends are not approved. GASOLINE/ETHER BLENDS: Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel. Other gasoline/ether blends are not approved. Operator s Manual 23

24 Preparing the Generator PRE-OPERATION CHECK COMPONENT PARTS: Check following items before starting engine: 1. Fuel leakage from fuel hose, etc. 2. Bolts and nuts for looseness. 3. Components for damage or breakage. 4. Generator not resting on or against any adjacent wiring. CHECK GENERATOR SURROUNDINGS: When listening to the radio near the generator, the radio sound may be disturbed on account of the radio wave condition and the radio performance. Make sure you review each warning in order to prevent fire hazard. WARNING: KEEP AREA CLEAR OF FLAMMABLES OR OTHER HAZARDOUS MATERIALS. KEEP GENERATOR AT LEAST 3 FEET (1 METER) AWAY FROM BUILDINGS OR OTHER STRUCTURES. ONLY OPERATE GENERATOR IN A DRY, WELL VENTILATED AREA. KEEP EXHAUST PIPE CLEAR OF FOREIGN OBJECTS. KEEP GENERATOR AWAY FROM OPEN FLAME. NO SMOKING! KEEP GENERATOR ON A STABLE AND LEVEL SURFACE. DO NOT BLOCK GENERATOR AIR VENTS WITH PAPER OR OTHER MATERIAL. 24 Operator s Manual

25 Operation OPERATION STARTING THE GENERATOR: CAUTION: CHECK THE OIL LEVEL BEFORE EACH OPERATION AS OUTLINED ON PAGE Make sure all appliances are disconnected from the generator. 2. Turn engine switch to the (CHOKE) position (Fig. 7). (When the engine is warm or temperature is high, start engine with the switch at (RUN) position). CAUTION: DO NOT CONNECT APPLIANCES WITH DEFECTIVE LINES AND/OR PLUGS. (Fig. 7) BE SURE APPLIANCES ARE NOT CONNECTED TO GENERATOR WHEN STARTING UP. STARTING THE GENERATOR WITH AN APPLIANCE CONNECTED COULD RESULT IN DAMAGE TO THE GENERATOR AND/OR APPLIANCE AND PERSONAL INJURY. 3. Pull the recoil starter handle slowly until passing the compression point (resistance will be felt), then return the handle to its original position and pull briskly. (Fig. 8) 4. After starting, allow the recoil starter handle to return to its original position with the handle still in your hand. Pull Briskly Recoil Starter Handle NOTE: If the engine fails to start after several attempts, repeat the starting procedures mentioned above with the engine switch placed at (RUN) position. 5. After 20 to 30 seconds of warm-up is completed, turn the engine switch to (RUN) position. (Fig. 9) 6. Make sure the output lamp is on. This indicates that the generator is properly operating. NOTE: Please consult with an authorized John Deere Dealer if the output lamp is off during the proper operation. 7. Test the GFCI receptacle on the unit. Push the test button. The reset button should pop out and there should be no power at the receptacle. Apply a test load or lamp to each receptacle to verify. IF THE RESET BUTTON DOES NOT POP OUT, DO NOT USE THE RECEPTACLE. SEE DEALER FOR SERVICE IMMEDIATELY. 8. If GFCI receptacle test correctly, firmly push the reset button to restore power. A distinctive click should be heard or felt when this is complete. IF THE RECEPTACLE DOES NOT RESET PROPERLY, DO NOT USE THE RECEPTACLE. SEE DEALER FOR SERVICE IMMEDIATELY. (Fig. 8) (Fig. 9) Operator s Manual 25

26 Operating the Generator OPERATION USING ELECTRIC POWER: WARNING: MAKE SURE THAT THE APPLIANCE IS SWITCHED OFF BEFORE CONNECTING IT TO THE GENERATOR. CONTROL PANEL DO NOT MOVE THE GENERATOR WHILE IT IS RUNNING. BE SURE TO GROUND THE GENERATOR. FAILURE TO GROUND UNIT MAY LEAD TO ELECTRICAL SHOCK. AC APPLICATION: 1. Make sure the output lamp is turned on. 2. Turn off the switch(es) of the electrical appliance(s) before connecting to the generator. 3. Insert the plug(s) of the electrical appliance(s) into the receptacle. (Fig. 10) Using Table 1, check appliance plug for compatibility with the generator receptacle. Be sure that the total wattage of all connected appliances does not exceed the rated output of the generator, see specifications on page 37. WARNING: BE SURE TO GROUND THE GENERATOR IF THE CONNECTED ELECTRICAL DEVICE IS GROUNDED. NOTE: The generator is equipped with an overload. If the generator shuts off during operation, the generator may be overloaded or the appliance may be defective. Stop the generator immediately, check the appliance and/or generator for overloading, and have repaired as necessary by an authorized John Deere Dealer. 4. Turn on the switch of the appliance. (Fig. 10) Style Receptacle AC plug Description NEMA 5-20R NEMA 5-15P NEMA 5-20P GFCI (Ground Fault Circuit Interrupter) Receptacle, duplex Table 1 26 Operator s Manual

27 Operating the Generator OPERATION DC APPLICATION: The DC terminal is used only for charging 12 volt batteries. It provides up to 12V - 8.3A (100W) of maximum power. (Fig. 11) CONNECTION OF CABLE: Connect positive terminal (red) on generator to positive (+) terminal on battery. Negative Terminal (Black) Positive Terminal (Red) Connect negative terminal (black) on generator to negative (-) terminal on battery. Both AC and DC output can be used at the same time if the total output is within rated output of the generator. SAFETY PRECAUTIONS WHILE CHARGING: (Fig. 11) WARNING: AN EXPLOSIVE HYDROGEN GAS IS DISCHARGED THROUGH VENT HOLES IN THE BATTERY DURING THE CHARGING PROCESS. DO NOT ALLOW SPARK OR OPEN FLAME AROUND THE GENERATOR OR BATTERY DURING THE CHARGING PROCESS. ELECTROLYTE FLUID CAN BURN EYES AND CLOTHING. BE EXTREMELY CAREFUL TO AVOID CONTACT. IF INJURED, WASH THE AFFECTED AREA IMMEDIATELY WITH LARGE QUANTITIES OF WATER AND CONSULT A DOCTOR FOR TREATMENT. When charging a large capacity battery or totally discharged battery, excessive current may force the DC breaker to turn off. Battery defects may cause the DC breaker to trip. Check the battery before resetting the DC breaker. (Fig. 12) STOPPING THE GENERATOR: 1. Turn off the power switch of the electric equipment and unplug the cord from receptacle of the generator. 2. Allow the engine about 3 minutes to cool down at no load before stopping. 3. Turn the engine switch to the position (STOP). (See Fig. 12) OIL SENSOR: The oil sensor detects the fall in oil level in the crankcase and automatically stops the engine when the oil level falls below a predetermined level. When the engine has stopped automatically, turn off the generator, and check the oil level. Refill engine oil to the upper level as instructed on page 21 and restart the engine. If the engine dose not start by usual starting procedures, check the oil level. CAUTION: DO NOT REMOVE OIL SENSOR PROBE WHEN REFILLING WITH OIL. REMOVE OIL FILLER CAP ON THE OPPOSITE SIDE OF CARBURETOR. Operator s Manual 27